Engine Harness and Connection Testing

• 1). Turn off the key switch and open the hood. Verify that the battery is free of corrosion, dirt and debris. If corrosion is found on the battery terminal, use baking soda and a small wire brush to remove the corrosion.
  
  
• 2). Inspect the engine harness to verify that it is free of corrosion, abrasion and damage. If damage is found, use electrical tape to temporarily repair the harness. Replace the harness if needed.
  
  
• 3). Inspect all of the electrical connections. Verify that the connection to the electronic control module and sensor is tight and secure.
  
  

Pressure Sensor Testing

• 1). Turn off the key switch. Disconnect the suspect pressure sensor from the engine harness. Remove the sensor from the pressure port.
  
  
• 2). Refer to the engine electrical schematic and remove the signal wire from the sensor electrical connector. Reconnect the sensor to the engine harness.
  
  
• 3). Turn on the key switch. Use the digital volt meter to measure the sensor output. Place the positive probe on the signal wire and place the negative probe on a clean chassis ground.
  
  
• 4). Refer to the engine schematic or engine manual to verify the sensor pressure range. Gradually apply a pressure to the sensor while monitoring the sensor output voltage. The voltage should change from approximately 0.5 volts, to 4.5 volts.
  
  

Temperature Sensor Testing

• 1). Turn off the key switch. Disconnect the temperature sensor from the engine harness. Remove the sensor from the engine port.
  
  
• 2). Refer to the engine electrical schematic and remove the signal wire from the sensor electrical connector. Reconnect the sensor to the engine harness.
  
  
• 3). Turn on the key switch. Measure the sensor output with the digital volt meter. Place the positive probe on the signal wire and place the negative probe on a clean chassis ground.
  
  
• 4). Gradually apply heat to the sensor while monitoring the sensor output voltage. The voltage should change from about 0.5 volts, to 4.5 volts.
  
  

Throttle Position Sensor Testing

• 1). Turn off the key switch. Disconnect the throttle sensor from the engine harness. Leave the sensor connected to the throttle assembly.
  
  
• 2). Refer to the engine electrical schematic and remove the signal wire from the sensor electrical connector. Reconnect the sensor to the engine harness.
  
  
• 3). Turn on the key switch. Measure the sensor output with the digital volt meter. Place the positive probe on the signal wire and place the negative probe on a clean chassis ground.
  
  
• 4). Move the throttle while monitoring the sensor output. The voltage should change from about 0.5 volts at low idle to 4.5 volts at full throttle.